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I joined Team Thogus a year and a half ago as the Tooling Manager. My responsibilities range from estimating/quoting, customer service, vendor/supplier relations, design, quality, purchasing, prototyping, production support, machining, coaching/mentoring, and mold maintenance. It’s true – I wear a lot of hats! But that is the beauty of this career field.

With more than twenty-five years of experience in the plastic injection molding manufacturing industry, wearing those many hats, I’ve come to the realization that “you” can determine the success and future from a career in manufacturing.

1. Innovation - Technology

Not trying to date myself but I remember creating drawings on a drafting board in shop class. Then, I was introduced to AutoCAD in the mid-80s, which was a huge advantage, because it opened opportunities for any job field that utilizes CADD (Computer Aided Drafting & Design).

Manufacturing isn’t working in a foundry pouring steel billets like my grandfather did decades ago, and like some people still do to this day. The industry has evolved with innovation and technology. For those that want to make chips on a milling machine or design the next innovative product using virtual reality, the opportunities are there – period.

Innovation goes hand-in-hand with manufacturing and always has. Power-generation systems using steam and water powered manufacturing equipment back in 1784. The assembly line introduction utilized electric back in 1870 to modernize mass production. In 1969, the first (PLC) programmable logic controller (or Robot) was used to automate production process. The future of manufacturing will be driven by (CPS) cyber-physical systems which allow for endless information to be shared in a manufacturing facility inside and outside their physical walls. The manufacturing industry and systems will not only optimize the process, but will analyze and communicate directly to execute tasks.

Going into manufacturing means you will experience innovation and technology. It’s not your grandfather’s factory.

2. Hands On

Most of the people that choose the manufacturing industry as a career path have either; taken something apart, tried to put to back together, sketched something on a piece of paper, grabbed a tool to fix something, visualized a product or process, or created something. Manufacturing reaches pretty much every aspect of our lives daily. So, I struggle when I hear that manufacturing has lost its appeal for the generations to follow because of previous views or perceptions of manufacturing. I will state, however, that the manufacturing industry is, and always be, a hands-on career, regardless of how you want to define hands-on.

The official definition of hands-on is, ‘involving or offering participation rather than theory.’ Is there no theory in manufacturing? Yes there is, but along with it, there are also people that must prove or disprove that theory.

For example: You walk into your garage and pick up a piece of wood. You have a concept in mind or on paper to transform that piece of wood. Then, you survey the garage to find the tools to “shape/transform” that piece of wood. Finally, you perform the task necessary to generate the final product. Yep, you guessed it, that is ‘manufacturing.’

That is the beauty of this industry. You are part of ‘making’.

3. Longevity

The manufacturing industry will always need people to support this career field. The world revolves around people making stuff, creating stuff, and providing stuff to all the other people in the world. My best recommendation to those considering the manufacturing industry is: there are multiple paths to follow and you will get out of it what you put into it. The part I most enjoy about my job is delivering the final product and/or service to my internal & external customers.

I highly recommend considering manufacturing as your career destination. You can find resources to help you. I have had the honor to work with Lorain County Community College’s Engineering program. If you are interested in manufacturing but don’t know where to start, check them out! Below is a snapshot from Lorain Community College’s Engineering & Manufacturing Pathway. LCC also offers the RAMP program (Retooling Adults for Manufacturing Programs).

I joined our team at Thogus Products Company nearly two years ago as a CSR. In my role, I provide B2B customer service for our proprietary line of hose and tube fittings, which are plastic injection molded fixtures such as tees, elbows, and adapters that are used in a multitude of industries, including agriculture, food and beverage, and automotive. The fittings accounts I service range in size from small, home-based businesses, to OEMs and distributors, to large automotive suppliers.

Here at Thogus, some of our Core Values are: Passion, Honesty & Integrity, Dedication, and Mutual Respect. Using these values as a foundation and a guide for the way that I engage my customers builds trust, and helps to foster relationships. A strong relationship with a customer will almost always lead to brand loyalty.

With more than twenty years of experience in the field of Customer Service, in a variety of capacities, including call center, retail, consumer affairs, and account management, I’ve picked up a few nuggets that have proven to be successful when engaging with the lifeline of any business – our valued customer.

1. Being proactive pays off.

I’ve learned that giving a heads-up can make all the difference to my customer. Especially if I happen tom be delivering news that’s not so great. For example, sending an email to inform the customer that their order will be delayed, or that one item on their order will need to be backordered. No one likes to be the bearer of bad news, and I’ve often braced myself for a scathing retort, cringing at the sight of the reply email, only to be pleasantly surprised by something along the lines of “That’s fine. Thank you for letting me know.”

Notifying your customer of potential delays or issues, providing them with information such as tracking numbers or copies of paperwork, before they request it, takes some of the pressure off, and makes their lives that much easier. As a result, you will stand out.

2. Small gestures go a long way.

While working in Consumer Affairs for a medical supply company, I would field numerous requests from end users for rubber walker tips. While routine protocol dictated that I refer the consumer to a local authorized dealer to purchase new tips, I would often send the tips out to the customer on our Goodwill account at no-charge. This small gesture that cost the company a mere few dollars at most meant the world to these consumers, most of whom were elderly. I would receive the nicest thank you notes gushing with gratitude.

The holidays and special occasions are another opportunity to let your customer know how much they are valued and appreciated, and it goes a long way in fostering the relationship. Is someone having a baby? Send a basket or a gift card to let them know you’re thinking of them. At Christmas, send customers gift baskets from your favorite local suppliers – cookies, popcorn, chocolate. Who doesn’t love receiving a tasty treat? While the treat will be enjoyable, the thought behind the gesture is invaluable.

3. Empathy is a must.

We need to be able to put ourselves in our customer’s shoes. We are customers too, and we have all been disappointed by an unfortunate set of circumstances when doing business with a company at some point in our lives. Think back to how the customer service associate handled the situation. Did they show compassion and understanding for your predicament? If so, did you feel that they were being sincere, or condescending? Sincerity is key when dealing with an unhappy customer. Make an honest effort to imagine how you would feel in the same situation, and what a CSR could do or say to quell your dissatisfaction. Being sincere in your empathy makes all the difference.

Nowadays, customers have so many choices when selecting goods and services. So much so, that businesses need to find a way to stand out. At our core, we all want to be valued, respected, and to feel that we matter. If you can make your customer feel like this, then I believe your customer will always choose you.

As a plastic injection molder, it surprised many when we entered the additive manufacturing industry with the creation of rp+m in 2012. Why would we entertain the thought of starting a company whose industry was considered a direct threat to plastic injection molding? Simple, we believed that this technology would pair well with injection molding.

While the two technologies may be complimentary, there are still times when one will be a better choice.

COST:

Plastic injection molding is the most popular method to make plastic parts. One reason is cost. If you need thousands of parts produced annually, plastic injection molding would be the most cost effective, even when factoring in the tooling. While a tool will cost thousands of dollars, the actual piece price for the part may run as low as a few cents (if a very small part made of a common polymer). Even small parts produced via additive manufacturing will cost tens of dollars per part – price for thousands of parts and you will quickly match the cost of plastic injection molding.

If you need a small plastic part made but only need a few of them – additive manufacturing is your better choice. When only a few parts are needed the cost for tooling in plastic injection molding is prohibitive. Additive manufacturing is the better choice for lower part quantities.

DESIGN ITERATIONS:

Sometimes you have a part design that isn’t quite there but you need to know where exactly the issues might be with the part. Additive manufacturing is your best choice. Your CAD design can be uploaded and the part made in hours. You can then have your part in-hand to review and decide what changes need to be made to the design.

TIME:

The time it takes to make your parts truly depends on the size and number of parts you need. If you need just a handful of parts, additive manufacturing is absolutely the most efficient choice to produce the parts. If thousands of parts are needed throughout the year, then plastic injection molding is your best choice when mass-producing.

QUALITY:

While there have been great strides in additive manufacturing to create high quality parts, injection molding can produce a part that typically has a better appearance to it and can be made with various surface finishes (including in-mold labeling and diamond-finishes).

Complexity in design with 3D printing

Overmolding and high gloss finish with injection molding

Even four years later we firmly believe that plastic injection molding and additive manufacturing are complementary technologies that can exist on their own or work together. If you have a part design but want to have the opportunity for design iterations before committing, you could have the part made via 3D printing and oncethe design is confirmed, then move forward to mass-production via injection molding. We are very excited to see what the next stages will be with additive manufacturing and how it will continue to work with plastic injection molding.

We at Thogus find plastic injection molding fascinating and while we recognize that this might not be the case for most, we do think the facts below are pretty interesting. Enjoy!

The first plastic injection molding machine was patented in the United States in 1872 by John Wesley Hyatt, with help from his brother.

The original purpose for the injection molding machine was to make billiard balls by injection celluloid into a mold. Celluloid went on to replace ivory in billiard ball production.

In 1946 the Injection Molding industry was revolutionized by American James Hendry when he updated Hyatt’s design from a plunger to a screw injection molding. To this day most plastic injection molding machines use this technique.

In the 1970s James Hendry also designed the first gas-assisted injection molding process, allowing for more complex parts to be made.

Design2Part is not limited to one specific industry which means we have the ability to network with a variety of companies.

Thogus is committed to supporting the region, and by taking part in this regional event, we feel this helps solidify that commitment. We want to make sure OEMs know we are here in their backyard to help them launch and manage their product lifecycles.

Quality of the attendees and exhibitors

Design2Part has been around for over 40 years, so the reputation of the event ensures that the attendees are coming to find solutions, not just kick the tires.

The top OEMs from the region will be exhibiting and that helps drive the right attendee.

Design engineers, purchasing, quality are just some of the attendees we look forward to seeing!

Personal touch

Emails and phone calls are fine but even in this day and age, nothing can replace face-to-face interactions. Let’s face it, we buy from people we like and that often means needing to sit down and have a real life conversation.

With over 300 product categories and thousands of attendees, this show provides the opportunity to network with numerous people not only to show what Thogus is capable of but also to learn about other technologies that can help us grow our business.

Join us on October 12 and October 13 at the John S. Knight Center in Akron, Ohio. You can find Russ, Matt, and Joe at booth 621 and learn about how Thogus can help you with your plastic injection molding and 3D printing needs!

Following part design and material selection the next step in plastic injection molding is getting the tool designed and made. One of the earliest decisions to make is whether to have a cold runner or hot runner system.

Cold Runner

When a mold is designed for a cold runner system, you have a channel formed between the two halves of a mold, allowing the plastic to move from the injection molding machine nozzle to the cavities. When the mold opens to eject the newly formed parts, the material in the runner system is also ejected, resulting in scrap material.

Hot Runner

This system is an assembly of heated components that inject molten plastic into the cavities of the mold. A hot runner system typically includes a heated manifold and a number of heated nozzles. When a mold with a hot runner system opens, only the part ejects as material in the runner system is kept molten and will fill into the part cavity during the next cycle.

So which do you choose?

Benefits of a Hot Runner System:

Eliminate the runner thus eliminating expensive scrap (and potential regrind issues) and you have less handling of materials.

Lower the cycle time since you are not waiting for the cold runner to cool during the cycle. Removing the runner also improves the injection screw recovery and injection time since due to the smaller shot size

Design flexibility because you can locate the gate at many points on the part

Downsides of a Hot Runner System:

Very expensive to design and build

Maintenance of the mold requires higher level of expertise

Complicated design

Benefits of a Cold Runner System:

Less expensive to manufacture

Lower maintenance costs

Easier to use for a wide variety of polymers

Downsides of a Cold Runner System:

Scrap waste through runner system and handling of materials

Potentially incorporating regrind into the system

When you are making the decision to choose between the a cold or hot runner system it is important to have a thorough understanding of your part, the material, and the estimated annual units. While hot runner systems are expensive to make, the scrap material waste and extended cycle time can offset the tooling savings.

My name is William Allen. I have been around plastics injection molding my entire life. My parents actually met while working in an injection molding facility as young adults and I can remember recognizing the sounds and smells of a plastics plant as early as five years old. When I found myself on the hunt for a job in 2005 I made my way into the plastics world as well. Starting out as an operator I was able to see plastics manufacturing from many angles as I worked my way up through the ranks. My first formal training in the realm of processing came in the form of a two day class and a one month crash course from a newly hired engineer on staff at Nampac (North American Packaging) which, at the time, was located in East Cleveland Ohio. That was in 2007. At the time, I was strictly working with polypropylene making one product – buckets - in several sizes and colors on the 11 presses we had in house. It wasn’t until midway through 2008, when Nampac closed its doors, that I joined the Thogus Products family as a process technician. I immediately started to realize just how many different plastics there were, and how much processing variation could exist in a facility that ran so many custom jobs.

Over the course of the next six years I enrolled in three additional technical training programs and gained a great deal of invaluable experience. My experience expanded across many different machines, several types of robots and automation, and of course multiple types and grades of plastic. Fast forward to March 2015, I was then offered an opportunity to be among the inaugural class of the AIM Institute in Erie Pennsylvania - an opportunity I will be eternally thankful for and know I will benefit from for the balance of my career.

Upon taking the entrance test for the AIM Institute (strictly for the sake of gauging current level of knowledge) I realized two things. First, this was not going to be a walk in the park. Second, I simply did not know nearly as much as I thought I did in the realm of injection molding. I was a fair mixture of nervous and excited. But, since I only had a week’s notice before the first of the four classes I was not able to do any research on what exactly I had signed up for; and therefore possibly less nervous than I would have been. Previously, I had read many articles both written by and written about John Beaumont, Mike Sepe and John Bozzelli and recognized them as leaders and pioneers in their respective corners of the plastics world. Little did I know that they would be among the instructors that would be teaching the AIM institute classes. I was a bit star-struck to say the least when I first entered the classroom and saw their name tags on the desks. I remember thinking “I might be out of my league here.” Turns out the mix of students in that class ranged from product design, to tooling, to processing and even quality control. The class, thankfully, is designed to work for anyone in the plastics world.

Throughout the next year I learned plastics - starting at the molecular level and working all the way through tool design, processing and even part review and design. The classes, while very challenging (even for the Thogus, degreed plastics engineer who was taking the class as well), were not the usual “take your information and go” type of classes. There was an enormous amount of support not only during the class and on the homework assigned between classes, but on any day of the week at any time. The instructors were just an email away and their responses were always prompt and informative. They want the students to succeed and their passion for the plastics industry was always evident. I admittedly had rough patches in some areas, but I was never completely lost. When I needed help it was always available.

In addition to the support from the instructors at the AIM Institute, the time allotted to me by my workplace to complete the WebEx classes and homework assignments was pivotal in my completion of the certification as well. Without Thogus’ support and encouragement throughout the program I may not have done as well or even have been able to complete and pass the classes. Their investment in me made an enormous difference in my ability to do well and directly impacted how much I was able to digest and retain the information.

After my grade for the final test came in and I received my certificate in the “Plastics Engineering and Technology” program I had a great sense of pride. I finished the class tied for the top grade, and while the class was not very large, I felt very accomplished. More importantly, I had a measurable increase in confidence. I was able to step up at work and take on a new role with new responsibilities. I bring a new understanding of troubleshooting to every situation and find myself narrowing in on a particular problem so that I can quickly investigate solutions. I am able to look at new designs and recognize potential issues before products are launched, which can make a world of difference once the steel is cut and processing begins. The lessons and education I was afforded by this program have made a world of difference for me in my day-to-day work. Learning real world applications from experts in a professional setting and having the homework and reinforcement between classes made the information stick. It was an experience I will never forget, and the confidence to challenge the industry standards, ask questions and strive to solve problems will be a staple in my career.

Plastic products are everywhere and the processes in which to make them are many. Knowing which process to choose for making a plastic part is key to making a quality part, and also to finding a supplier that can help you achieve your production goals.

So, how do you choose? Let’s look at some of the most common processes used to make a plastic part:

1. Blow molding

Typical Use: Blow molding is typically used in the making of hollow parts, like bottles, that have a uniform wall thickness.

Overview of the Process: The first step in blow molding is the creation of a resin parison or a preform. A parison is a tube-like shape of plastic with a hole in one end that allows pressurized air to pass through. The parison is then clamped into the machine and air pressure is used to inflate the material which fills up the mold and creates the desired shape.

Variations of the Technology: Within the technology there are three types; extrusion blow molding, injection blow molding, and injection stretch molding.

2.Thermoforming

Typical Use: Within thermoforming there are two categories: Thin-gauge and thick-gauge. Thin-gauge thermoforming requires sheets less than .060in thick (1.5mm) and thick-gauge, the sheets are greater than .120in thick (3mm). Trays and packaging for medical, food, and retail are created using thin-gauge and larger items like plastic pallets, bumpers, refrigerator lines are made using thick-gauge thermoforming.

Overview of the Process: A plastics sheet is heated until it is pliable and placed over or between a steel mold of the shape to form customized plastic products. Typically thermoforming is done in a continuous, high-speed process where thousands of parts are made each hour.

Typical Use: Rotational molding is typically used when making hollow parts that require uniform wall thickness such as tanks or kayak bodies.

Overview of the Process: A mold is filled with a polymer resin – typically in powder form; the resin is then heated to a molten state while the mold rotates bi-axially so that the resin coats the inside of the mold cavity in a uniform fashion. Once cooled the part is removed from the mold.

Variations of the Technology: Much of the variation in rotational molding lies in the production equipment itself. There are a variety of methods used to actually rotate the molds: Rock and Roll, Clamshell, Carousel, Vertical, Shuttle and Swing Arm machines to name a few. Rotational molding often times is confused with rotational or spin casting which have slight variations that make them different than rotational molding.

4. Extrusion

Typical Use: Extrusion is used to make products that have linear and fixed cross-sectional profiles such as pipe, hose, and fenestration products; and is the reason why extrusion is often times referred to as profile extrusion.Extrusion is also one of the most common processes used to make compounded plastic pellets for extrusion or injection molding.

Overview of the Process: Either plastic compounded pellets or a dry blend of chemicals are placed into the material hopper and then loaded into the barrel of the extrusion machine where they are heated and worked along a screw to the end of a machine where they exit through a die. The die shape dictates the ultimate dimensions of the profile coming out of the machine. The shape or profile is then cooled and cut to the desired length. Because of the length requirements, often times extrusion equipment can take up an extensive amount of space on a shop floor.

Variations of the Technology: Often the screw does the majority of the work to extrude the product through the die, but in highly filled polymers such as fiber-reinforced profiles sometimes a method of pulltrusion is employed where the extrudate is pulled through a long die.

5. Injection molding

Typical Use: Injection molding is the most common method of manufacturing plastic parts and is ideal when production of a single part is of high volume. Injection molding allows for a fast rate of production, the ability to have many textures, finished, colors and complex parts.

Overview of the Process: Similar to extrusion, plastic compounded pellets are loaded into the barrel of a machine where the material is melted and worked down the length of a screw. Unlike extrusion, however, instead of exiting the machine through a die, the material is pushed through a runner system into a closed mold made of steel in the shape of the desired part. The mold goes through a heating and cooling cycle and once the desired temperatures and time settings are achieved the mold opens and the part can be removed.

Variations of the Technology: Much of the variation that exists in injection molding has to do with the way in which the injection molding machine itself is positioned (vertical or horizontal) and also the way the tool is designed. Tooling and the machine are always dictated by the complexity of the part and the volumes that need to be achieved while optimizing manufacturing efficiencies.

Now that you know the processes let’s refer to a chart for advantages and disadvantages of each as it relates to potential applications.

Guest post from our own James Michalenko and his transition from the military to the workforce!

When I thought about what I wanted to do for a career as a high school graduate, I only knew that I wanted it to be fun, exciting and challenging. So I decided to join the United States Marine Corps Reserves while I decided on college. The Marine Corps Infantry delivered just about everything that I was looking for, but I realized it wasn't what I wanted to do long-term. After returning from boot camp, my father told me about a Plastics Engineering Technology program at The Behrend College, Pennsylvania State University in Erie, Pennsylvania. The main selling point at that time, in 2004, was that the industry was relatively young and the job placement was 99.0% coming out of the program. I decided to try it out and quickly realized that it could possibly deliver the challenge I was looking for. I believed it could also occupy and interest me with all of the different types of manufacturing and engineering opportunities that exist, relative to the industry. In 2005, I was soon pulled out of college and the Plastics Engineering Technology program to serve overseas in Iraq. Returning back to school was difficult, however, the technical exposure, opportunity and the humming of an injection molding machine quickly got me back into plastics engineering and manufacturing. Today, I experience more opportunities to engineer applications and products than I could have ever imagined. The troubleshooting, critical thinking and discipline, among other things, that I developed while in the Corps, prepared me well for the manufacturing leadership position I hold today. It is obvious that the industry is still developing beyond what it was when I joined, and there is still much to be learned and redefined in the industry. It's exciting to be apart of the plastics industry.

Cleveland has been called a lot of things: Mistake on the Lake; the buckle on the rust belt; unhappiest place to work, most miserable city, dirtiest city – all thanks to Forbes magazine (they do not appear to be fans of ours). But to those of us at Thogus, Cleveland is the phoenix rising from the ashes. We are tough, we are resourceful, we are proud. Just like Cleveland, manufacturing in Northeast Ohio is the same. We are tough. We are resourceful. We are proud.

The past few years have been a great time in Cleveland. Of course, most people know about our beloved son, LeBron James, and his redemptive return home which helped bring our Cavaliers back to a finals appearance in 2015. Cleveland was host to the 2013 National Senior Games, 2014 Gay Games, 2015 Content Marketing World, and will host the 2016 Republican National Convention. We are becoming a destination, not a stopover.

Our downtown and surrounding inner cities are booming with residents, restaurants, and retail. People are moving back to Cleveland more than they have in years! We are becoming a foodie destination due to chefs like Michael Symon, Jonathon Sawyer, Zack Bruell, Rocco Whalen, and Doug Katz. Great Lakes Brewing Company, Fat Heads, and Platform Brewery are just a few of the local craft breweries you can find on the North Coast.

None of these would be possible without the manufacturers who drive our economy and create our jobs. Vitamix, Parker Hannifin, Eaton, Lincoln Electric, PolyOne, and Sherwin Williams are just a few examples of our strength as a destination of world-class manufacturing. We are makers. We are doers.

As we look towards the future, Thogus is keeping a steady eye on what possibilities are next. With the strength of our medical community we know that new innovations and technologies in medicine will be discovered right here. The tech world is seeing Cleveland as a new hub for activity and possibilities. We are home to world-class universities that are acting as incubators for up-and-coming companies. And Thogus will be helping make reality the ideas that these companies come up with. It is what we do. If you want to see what the next generation of manufacturing looks like, come see us! We will show you what the future looks like, today.